Valve

ABSTRACT

Various embodiments of the present disclosure provide a reusable valve in which a seal portion is co-molded with and overmolded to the valve stem to provide a secure mechanical bond therebetween. In one embodiment, the valve includes a snap fit between the valve stem and a retaining cap to provide easy assembly of the valve as well as an efficient and compact retention mechanism for a biasing spring and the valve stem in relation to the valve housing. In one embodiment, the valve includes an easy-to-use opening and closing mechanism that provides tactile feedback to the user when moving the valve stem to an open position and to a closed position to inflate, deflate, or maintain air or gas pressure in the inflatable article. The present disclosure also provides a dunnage bag with such valve.

PRIORITY CLAIM

This application is a continuation of, and claims priority to and thebenefit of, U.S. patent application Ser. No. 15/360,390, which was filedon Nov. 23, 2016, which is a continuation of, and claims priority to andthe benefit of U.S. patent application Ser. No. 14/445,903, which wasfiled on Jul. 29, 2014, now U.S. Pat. No. 9,505,334, which issued onNov. 29, 2016, which claims priority to and the benefit of U.S.Provisional Patent Application No. 61/862,216, which was filed on Aug.5, 2013, and is now expired, the entire contents of each of which areincorporated herein by reference.

BACKGROUND

Inflatable dunnage bags are commonly used to stabilize cargo duringtransportation of cargo containers (such as railroad cars andsemi-trailers), thereby improving safety and reducing the likelihood ofdamage to the cargo. Dunnage bags are commonly inflated and deflatedbefore and after use through valves configured for this purpose. Dunnagebags may be positioned in any voids or spaces between the cargo and/orbetween the cargo and the walls of the cargo container and inflated to adesired internal pressure, such as a designated operating pressure.

To inflate a dunnage bag, the user connects a pressurized air supply tothe valve, which is attached to the inflatable/deflatable body of thedunnage bag and which forms an opening in the dunnage bag. The userpositions the dunnage bag in the appropriate void or space and theninflates the dunnage bag to the desired internal pressure usingpressurized air from the pressurized air supply. When the dunnage bagneeds to be repositioned during inflation, the user opens the valveassociated with the dunnage bag to enable the air from within thedunnage bag to escape, partially deflating the dunnage bag. The valve isthen closed and the dunnage bag can be repositioned and inflated to thedesired internal pressure, such as the designated operating pressure.When the dunnage bag needs to be removed from its position between thecargo or between the cargo and the walls of the cargo container toenable the cargo to be offloaded from the cargo container, the useropens the valve associated with the dunnage bag to enable the air fromwithin the dunnage bag to escape to deflate the dunnage bag.

During inflation, the pressure inside the dunnage bag is significantlylower than the pressure upstream of the valve due to backpressure causedby the valve itself. During deflation, dunnage bags or bag walls havebeen known to interfere with the valve opening, thereby impeding theescape of air for proper deflation. Additionally, certain dunnage bags,such as dunnage bags manufactured from paper, have been known to have areduced burst pressure limit when used in connection with known valves.In certain cases, known valves lack the capability for high flow ratesand/or are not reusable. Known valves also typically include complicatedsealing mechanisms to prevent the leakage of air from an inflateddunnage bag.

Accordingly, there is a need for a new and improved valve that solvesthese problems, and for new and improved dunnage bags having such newand improved valves.

SUMMARY

Various embodiments of the present disclosure provide a reusable valvein which a seal portion is co-molded with and overmolded to the valvestem to provide a secure mechanical bond therebetween. In oneembodiment, the valve includes a snap fit between the valve stem and aretaining cap to provide easy assembly of the valve as well as anefficient and compact retention mechanism for a biasing spring and thevalve stem in relation to the valve housing. In one embodiment, thevalve includes an easy-to-use opening and closing mechanism thatprovides tactile feedback to the user when moving the valve stem to anopen position and to a closed position to inflate, deflate, or maintainair or gas pressure in the inflatable article. In one embodiment, thevalve minimizes backpressure during inflation of the inflatable article.In one embodiment in which the valve is employed to inflate and deflatea dunnage bag, the valve is suitable for use with higher dunnage bagburst pressures when the dunnage bag is made from paper while maximizingthe flow rate of air through the valve. This solves the above problems.

More specifically, in one embodiment, the valve includes: (a) a housingincluding: (i) a flange configured to mount the valve to an inflatablearticle, (ii) an outer wall extending from the flange, and (iii) anannular wall extending radially inward from the outer wall and away fromthe outer wall in a direction of flow associated with inflation of theinflatable article; (b) a stem connected to the housing and moveable toan open position and to a closed position relative to the housing, thestem including a shaft and a base extending radially outward from theshaft and away from the shaft in the direction of flow associated withinflation of the inflatable article; (c) a spring biasing the stemtoward the closed position relative to the housing; (d) a key connectedto the stem and configured to retain the spring and the stem relative tothe housing and to enable movement of the stem to the closed positionand to the open position; and (e) a handle removably connected to thehousing, the handle positionable opposite the flange to secure a wall ofthe inflatable article therebetween.

In another embodiment, the valve includes: (a) a housing including: (i)a flange configured to mount the valve to an inflatable article, (ii) anouter wall extending from the flange, and (iii) an annular wallextending radially inward from the outer wall and away from the outerwall in a direction of flow associated with inflation of the inflatablearticle; (b) a stem connected to the housing and moveable to an openposition and to a closed position relative to the housing, the stemincluding (i) a shaft; (ii) a base extending radially outward from theshaft and away from the shaft in the direction of flow associated withinflation of the inflatable article; and (iii) one or more wallsdefining a first slot and one or more walls defining a second slotadjoining the first slot, the one or more walls defining the first slotpermitting a first direction of motion of the stem and the one or morewalls defining the second slot permitting a second different directionof motion of the stem, the one or more walls defining the first slot andthe one or more walls of the second slot configured to receive aprotrusion connected to the housing; (c) a spring biasing the stemtoward the closed position relative to the housing; (d) a key snap fitwith the stem and abutting the spring to retain the spring and the stemrelative to the housing, the key configured to enable movement of thestem to the closed position and to the open position; and (e) a handleremovably connected to the housing, the handle positionable opposite theflange to secure a wall of the inflatable article therebetween.

In another embodiment, the present disclosure relates to a dunnage bagincluding: an inflatable/deflatable body including one or more walls;and an inflation/deflation valve mounted to the body, the valveincluding (a) a housing including: (i) a flange configured to mount thevalve to the dunnage bag, (ii) an outer wall extending from the flange,and (iii) an annular wall extending radially inward from the outer walland away from the outer wall in a direction of flow associated withinflation of the dunnage bag; (b) a stem connected to the housing andmoveable to an open position and to a closed position relative to thehousing, the stem including a shaft and a base extending radiallyoutward from the shaft and away from the shaft in the direction of flowassociated with inflation of the inflatable article; (c) a springbiasing the stem toward the closed position relative to the housing; (d)a key connected to the stem and configured to retain the spring and thestem relative to the housing and to enable movement of the stem to theclosed position and to the open position; and (e) a handle removablyconnected to the housing, the handle positionable opposite the flange tosecure one of the one or more walls of the dunnage bag therebetween.

Additional features and advantages of the present disclosure aredescribed in, and will be apparent from, the following DetailedDescription and the Figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of one embodiment of a valve of thepresent disclosure.

FIG. 2 is a bottom perspective view of the valve of FIG. 1.

FIG. 3 is a top perspective exploded view of the valve of FIG. 1.

FIG. 4 is a bottom perspective exploded view of the valve of FIG. 1.

FIG. 5 is a side cross sectional view of the valve of FIG. 1 showing thevalve in a closed position.

FIG. 6 is a side cross sectional view of the valve of FIG. 1 showing thevalve in an open position.

FIG. 7 is a top perspective section view of the valve of FIG. 1 showingthe valve in a closed position.

FIG. 8 is a top perspective section view of the valve of FIG. 1 showingthe valve in an open position.

FIG. 9 is a side section view of the valve of FIG. 1 showing the valvein an open position and showing the direction of airflow duringinflation of an inflatable article.

FIG. 10 is a top perspective view of the stem and key of the valve ofFIG. 1.

FIG. 11 is a side elevation view of the stem and key of FIG. 10 showingthe stem in a closed position relative to the valve housing.

FIG. 12 is a side elevation view of the stem and key of FIG. 10 showingthe stem in a partially open position relative to the valve housing.

FIG. 13 is a side elevation view of the stem and key of FIG. 10 showingthe stem in an open but unlocked position relative to the valve housing.

FIG. 14 is a side elevation view of the stem and key of FIG. 10 showingthe stem in an open and a first locked position relative to the valvehousing.

FIG. 15 is a side elevation view of the stem and key of FIG. 10 showingthe stem in an open and a second locked position relative to the valvehousing.

FIG. 16 is a partial detail section view of the stem, key, and spring ofthe valve of FIG. 1.

FIGS. 17A and 17B illustrate top perspective and bottom perspectiveviews of another embodiment of the handle.

DETAILED DESCRIPTION

Various embodiments of the present disclosure provide a reusable valvein which a seal portion is co-molded with and overmolded to the valvestem to provide a secure mechanical bond therebetween. In oneembodiment, the valve includes a snap fit between the valve stem and aretaining cap to provide easy assembly of the valve as well as anefficient and compact retention mechanism for a biasing spring and thevalve stem in relation to the valve housing. In one embodiment, thevalve includes an easy-to-use opening and closing mechanism thatprovides tactile feedback to the user when moving the valve stem to anopen position and to a closed position to inflate, deflate, or maintainair or gas pressure in the inflatable article. In one embodiment, thevalve minimizes backpressure during inflation of the inflatable article.

It should be appreciated that the valve of the present disclosure may beused in connection with any suitable inflatable articles such as, butnot limited to dunnage bags, bags other than dunnage bags, airmattresses, rafts, tires, structures, and/or boats.

Referring now to the drawings, FIGS. 1 to 16 illustrate one embodimentof the valve of the present disclosure, which is generally indicated bynumeral 10, being used in connection with a dunnage bag. In thisembodiment, valve 10 includes: (a) housing 20 configured to mount to adunnage bag (shown generally by numeral 70); (b) stem 30 connected toand moveable relative to housing 20, and configured to open and closepassage 96 for a suitable gas such as air to pass to and from aninternal portion (not shown) of dunnage bag 70; (c) spring 40 to biasstem 30 toward a closed position relative to housing 20; (d) key 50 toretain spring 40 and stem 30 relative to housing 20 and to enable a userto move stem 30 to a closed position and to an open position; and (e)handle 60 to secure valve 10 to dunnage bag 70 and to enable a user toeasily grip and externally manipulate valve 10, handle 60 including cap62 to cover and protect passage 96 to be free from dust and debris whenvalve 10 is not in use by the user.

In this embodiment, housing 20 (as best shown in FIGS. 3 to 8) includes:(a) flange 80 configured to be secured to a wall of dunnage bag 70; (b)annular protrusions 82 forming grooves 83 therebetween to receive andremovably retain handle 60 to housing 20; (c) annular ring 84 to receiveand removably retain cap 62 of handle 60 to housing 20 and to receiveand removably secure an inflation device to valve 10 to inflate dunnagebag 70; (d) one or more walls defining aperture 86 to receive and engagewith stem 30; (e) protrusion 88 (as best shown in FIGS. 11 to 15)extending radially inward from the one or more walls defining aperture86 and configured to slidably engage with a receiving portion of stem 30to permit a user to move stem 30 to an open position and to a closedposition; (f) a plurality of supports 90 (as best shown in FIGS. 1, 5and 6) configured to support the one or more walls defining aperture 86relative to outer wall 92; (g) seat 94 configured to mate with stem 30to seal valve 10 when in the closed position; (h) wall 98 extendinginwardly and downwardly away from opening 102 of outer wall 92 to formaperture 100 to reduce backpressure of air flowing through valve 10; and(i) standoffs 104 extending from a bottom surface of flange 80 to helpprevent dunnage bag 70 from sealing itself to the bottom of valve 10thereby facilitating easier deflation of dunnage bag 70. Housing 20 mayinclude a plastic, such as polyethylene. Spring 40 may include a steel,such as a stainless steel or a corrosion resistant steel.

In this embodiment, annular protrusions 82 are positioned relative toflange 80 along an outer portion of outer wall 92 and are configured toreceive handle 60 at any of a plurality of different locations alongouter wall 92 to permit attachment of valve 10 to dunnage bag 70. Inthis way, valve 10 can accommodate and be installed upon dunnage bag 70having a range of wall thicknesses, including the wall thicknesses ofall substrate layers associated with or used in combination with dunnagebag 70.

In this embodiment, stem 30 (as best shown in FIGS. 3 to 4 and 10 to 16)includes: (a) shaft 120 to slidably engage with the one or more wallsdefining aperture 86 of housing 20; (b) body portion 122; (c) seal 124;(d) rib 126; (e) one or more walls defining slot 128 and slot 130 toreceive and engage with protrusion 88 (as best shown in FIGS. 11 to 15);(f) chamfer 132 to engage with protrusion 88; (g) shoulder 136; and (h)head 134 configured to engage with key 50 and including (1) top portion138, (2) recessed body portion 140, and (3) lip 142. In one embodiment,seal 124 is co-molded with body portion 122 via, for example, aninjection molding process, thereby causing seal 124 to be integrallyformed as a part of stem 30. In this way, a secure mechanical bond isformed between seal 124 and body portion 122 of stem 30. In oneembodiment, stem 30 includes a plastic, such as polypropylene. In oneembodiment, seal 124 is made from or includes an elastomer, such as avulcanized elastomer or a thermoplastic vulcanizate. For example, asuitable material for seal 124 is SANTOPRENE® (SANTOPRENE is aregistered trademark of Monsanto Company Corporation), which ismanufactured by ExxonMobil Chemical. It should be appreciated that othermaterials can be employed for the seal.

Body portion 122 (as best shown in FIGS. 4, 7, 8, and 10) is configuredin the shape of a hollow cone with an open base where rib 126 providesrigidity to body portion 122 while also permitting material savings inthe manufacture of stem 30. The cone of body portion 122 extendsdownwardly and outwardly from or near the base of shaft 120 to reducebackpressure of air flowing through valve 10. The one or more wallsdefining slot 128 generally extend longitudinally along a portion ofshaft 120, and are configured to captively receive protrusion 88 ofhousing 20. The one or more walls defining slot 128 are configured topermit stem 30 to longitudinally translate to enable opening and closingof valve 10. The one or more walls defining slot 130 extend laterally atan angle from the one or more walls defining slot 128 to permit captiverotation of stem 30 by the one or more walls defining aperture 86. Inthis embodiment, the angle is approximately 90 degrees but could, inother embodiments, be a different angle. The one or more walls definingslot 130 are configured to enable the user to lock stem 30 into an openposition relative to housing 20 to permit air to enter or escape fromdunnage bag 70. In one embodiment, the one or more walls defining slot130 are curved. Chamfer 132 is configured to transition stem 30 duringactuation of valve 10 toward an open or toward a closed position.

In this embodiment, key 50 (as best shown in FIGS. 10 and 16) includes:(a) female portion 160 to engage with top portion 138 of head 134; (b)one or more walls defining aperture 162 configured to abut or lie inproximity to recessed body portion 140; (c) shoulder 164 configured tobe overlapped by lip 142 after assembling key 50 to stem 30 to permitretention of spring 40 and stem 30 relative to housing 20; (d) recess166; (e) annular protrusion 168 configured to abut an outer periphery ofshaft 120 of stem 30; (f) shoulder 170 configured to abut an end coil ofspring 40 to retain spring 40 relative to housing 20; (g) protrusions172 oriented on a periphery of body 174 to enable a user's fingers togrip key 50 to open and close valve 10; and (h) bottom surface 176configured to mate with shoulder 136 of stem 30. In this embodiment,female portion 160 provides a snap fit with top portion 138. In thisembodiment, top portion 138 and female portion 160 include conicalshapes to aid the assembly of female portion 160 with top portion 138,but may, in other embodiments, have other suitable shapes. Key 50 mayinclude a plastic, such as polypropylene.

In this embodiment, handle 60 (as best shown in FIGS. 3 and 4) includes:(a) cap 62; (b) tether 180 flexibly connecting cap 62 to body 182; (c)grip 184 including one or more walls defining aperture 186; and (d)spaced apart tabs 188 extending inwardly from aperture 190 defined byone or more walls of body 182 to removably engage with annularprotrusions 82 of housing 20. Handle 60 may include a plastic, such aspolypropylene.

In this embodiment, cap 62 includes: (a) tab 200 extending from cap 62to permit the easy removal of cap 62 from housing 20 when installedthereon; and (b) protrusions 202 extending inwardly from an innersurface of cap 62 and which are configured to engage with annular ring84 of housing 20 to removably retain cap 62 to housing 20. Protrusions202 provide a snap fit with annular ring 84. Cap 62 is configured toreceive indicia on an outer surface of cap 62. In this embodiment, theindicia is integrally formed as a part of cap 62.

In this embodiment, spaced apart tabs 188 are configured to deflect uponinstallation of handle 60 onto housing 20 and lie at least partially inor about one or more grooves 83 and/or one or more annular protrusions82 of housing 20. Dunnage bag 70, including all plies, layers andsubstrates associated with a wall of dunnage bag 70, is configured tolie between flange 80 of housing 20 and body 182 to thereby secure valve10 to dunnage bag 70. Valve 10 may be loosened from any external pliesof dunnage bag 70 by removing handle 60 from housing 20.

In this embodiment, the closed position of valve 10 is the appropriateposition for beginning the process of inflating dunnage bag 70. In thisembodiment, an inflation device may be configured to press against thekey to cause stem 30 to move thereby opening valve 10. In thisembodiment, stem 30 moves to, but need not lock in, an open position.Dunnage bag 70 is then inflated to the desired pressure and theinflation device is removed from valve 10, thus closing valve 10. Duringinflation, the angle of wall 98 of housing 20 and the angle of bodyportion 122 of stem 30 individually and together minimize backpressureof the flow of air through valve 10 by minimizing changes in thedirection of the flowing air and by gradually changing the direction ofthe air when needed. In one embodiment, the inflation device engageswith annular ring 84 to secure the inflation device onto housing 20.

To open valve 10 when initially in the closed position to at leastpartially deflate dunnage bag 70, a user would grip key 50 andpotentially protrusions 172 and push against the force provided byspring 40 in a direction of travel provided by the one or more wallsdefining aperture 86 and the combination of protrusion 88 and the one ormore walls defining slot 128. To position stem 30 in a self sustainingopen position, a user would, in addition to pushing against spring 40,rotate key 50 and therefore stem 30 in a direction of travel provided bythe combination of protrusion 88 and the one or more walls defining slot130. The user would rotate key 50 and therefore stem 30 in acounter-clockwise manner at least until the tension of spring 40 istaken up by the one or more walls defining slot 130. Chamfer 132 helpsguide protrusion 88 toward the walls defining slot 130 when openingvalve 10 and away from the walls defining slot 130 when closing valve10. When in the open position, valve 10 is configured to deflate dunnagebag 70. The rotation and translation of stem 30 described above many bereversed to seat seal 124 upon seat 94 to close valve 10.

FIGS. 17A and 17B illustrate another embodiment of the handle, which isgenerally indicated by numeral 1060. In this embodiment, handle 1060includes: (a) cap 1062; (b) first tether 1180 flexibly connecting cap1062 to body 1182; (c) grip 1184 including one or more walls definingaperture 1186; (d) second tether 1181 flexibly connecting grip 1184 tobody 1182, and (e) spaced apart tabs 1188 extending inwardly fromaperture 1190 defined by one or more walls of body 1182 to removablyengage with annular protrusions 82 of housing 20.

In this illustrated embodiment, cap 1062 includes: (a) tab 1200extending from cap 1062 to permit the easy removal of cap 1062 fromhousing 20 when installed thereon; and (b) protrusions 1202 extendinginwardly from an inner surface of cap 1062 and which are configured toengage with annular ring 84 of housing 20 to removably retain cap 1062to housing 20. Protrusions 1202 provide a snap fit with annular ring 84.Cap 1062 is configured to receive indicia on an outer surface of cap1062. In this illustrated embodiment, the indicia is integrally formedas a part of cap 1062.

It should be appreciated that the embodiment of the valve illustrated inthe accompanying Figures employs one example configuration of componentsand one example size and shape of each of the components. It should beappreciated that other embodiments of the valve may employ differentconfigurations of the components and/or components of different sizes orshapes.

It should be understood that modifications and variations may beeffected without departing from the scope of the novel concepts of thepresent disclosure, and it should be understood that this application isto be limited only by the scope of the appended claims.

The invention is claimed as follows:
 1. A valve comprising: a housingcomprising a protrusion and an annular wall, the annular wall at leastpartially defining a fluid flow passage; and a stem comprising a shaftand a base, the shaft defining a first slot configured to receive theprotrusion, wherein when the protrusion is positioned in the first slot,the stem is movable relative to the housing between an open position inwhich the fluid flow passage is open and a closed position in which thefluid flow passage is closed.
 2. The valve of claim 1, furthercomprising a biasing element that biases the stem to the closedposition.
 3. The valve of claim 2, further comprising a key attached tothe stem, the key retaining the biasing element in place.
 4. The valveof claim 1, wherein the stem is lockable in the open position viarotation of the stem relative to the housing.
 5. The valve of claim 4,wherein the shaft defines a second slot that extends transversely fromthe first slot.
 6. The valve of claim 5, wherein the second slot isperpendicular to the first slot.
 7. The valve of claim 5, wherein thestem is in a first rotational position when the protrusion is positionedin the first slot.
 8. The valve of claim 7, when the stem is in the openposition, the stem is rotatable from the first rotational position to asecond rotational position to cause the protrusion to move from thefirst slot to the second slot.
 9. The valve of claim 8, wherein the stemis retained in the open position when the protrusion is positionedwithin the second slot.
 10. The valve of claim 9, wherein a wallpartially defining the first slot prevents the stem from rotating fromthe first rotational position to the second rotational position unlessthe stem is in the open position.
 11. The valve of claim 1, wherein thehousing further comprises a valve seat, and wherein the base of the stemsealingly engages the valve seat when the stem is in the closedposition.
 12. The valve of claim 11, wherein the base of the stem isspaced apart from the valve seat when the stem is in the open position.13. The valve of claim 12, wherein the base of the stem comprises anelastomeric seal that sealingly engages the valve seat when the stem isin the closed position.
 14. The valve of claim 11, wherein the annularwall comprises the valve seat.
 15. An inflatable article comprising: aninflatable/deflatable body including one or more walls; and aninflation/deflation valve mounted to the body, the valve including: ahousing comprising a protrusion and an annular wall, the annular wall atleast partially defining a fluid flow passage; and a stem comprising ashaft and a base, the shaft defining a first slot configured to receivethe protrusion, wherein when the protrusion is positioned in the firstslot, the stem is movable relative to the housing between an openposition in which the fluid flow passage is open and a closed positionin which the fluid flow passage is closed.
 16. The inflatable article ofclaim 15, wherein the stem is lockable in the open position via rotationof the stem relative to the housing.
 17. The inflatable article of claim16, wherein the shaft defines a second slot that extends transverselyfrom the first slot.
 18. The inflatable article of claim 17, wherein thestem is in a first rotational position when the protrusion is positionedin the first slot.
 19. The inflatable article of claim 18, when the stemis in the open position, the stem is rotatable from the first rotationalposition to a second rotational position to cause the protrusion to movefrom the first slot to the second slot.
 20. The inflatable article ofclaim 19, wherein the stem is retained in the open position when theprotrusion is positioned within the second slot.